Manufacturing method of a speaker vibrating diaphragm by controlling a ratio of fiber materials

ABSTRACT

The invention discloses a manufacturing method of a speaker vibrating diaphragm by controlling a ratio of fiber materials, the method comprising the steps of: (A) fabric provision: providing a fabric interwoven by a plurality of warps and a plurality of wefts; (B) impregnation: impregnating the fabric in a resin solution; (C) drying: drying the fabric impregnated with resin solution; (D) formation: pressing the dried resin-impregnating fabric to form a predetermined shape; and (E) cutting: cutting the formed speaker vibrating diaphragm from the fabric. Each of the plurality of warps and each of the plurality of wefts of the fabric has an individual yarn count and material composition. By controlling a combination of the yarn counts of the plurality of warps and the plurality of wefts, a total number of threads and a material composition ratio of the warps and wefts required for the vibrating diaphragm are achieved.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/465,952, filed on Mar. 22, 2017, which is incorporatedherewith by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates generally to a manufacturing method of aspeaker vibrating diaphragm, and more particularly, to a manufacturingmethod of a speaker vibrating diaphragm by controlling the ratio offiber material.

2. The Prior Arts

Referring to FIG. 1, a typical moving coil 10 includes a power system, acone paper 11 and a suspension. The power system further includes amagnet 15, a pole piece, a basket assembly and a voice coil 14. The conepaper 11, which is a vibrating diaphragm for moving air, is typically asound cone in conical shape or hemispherical shape. The suspension iscomposed of a damper 12 and a connecting member 13 etc., for drawing adirectional movement of the vibrating diaphragm. The operation principleis that when current flows through the voice coil 14, an electromagneticfield perpendicular to the magnetic field of the permanent magnet 15 ofthe speaker is generated, forcing the voice coil to move within the gap(the gap between the voice coil 14 and the magnet 15). The mechanicforce generated by the movement allows the cone paper 11 attached on thevoice coil 14 to produce a perpendicular and up-down movement(vibration), so that the air is vibrated to make a sound to be perceivedby human ears, thereby implementing a conversion of electric energy tosound energy.

The variety of nonmetal parts inside the conventional speaker 10, suchas the cone paper 11, the damper 12 etc., are manufactured by originalfabrics; this is because the original fabrics processed by specialtreatment possesses an appropriate elasticity and intensity that fulfillthe function requirements for operating the speaker. These nonmetalparts are collectively called speaker vibrating diaphragms. Aconventional method for manufacturing speaker vibrating diaphragmsincludes steps of resin impregnation, drying, formation, and cutting, toform the final product of speaker vibrating diaphragms.

Although the speaker vibrating diaphragms only accounts for a very smallpercentage of the cost of the overall speaker, the speaker vibratingdiaphragms play critical roles in affecting the sound quality of thespeaker. As a result, the manufacturing method of high-quality speakervibrating diaphragms which fulfill various environmental requirementsbecomes very important.

Specifically, the fabric material used for manufacturing a conventionalspeaker vibrating diaphragm is the essential and fundamental structureof the speaker vibrating diaphragm. However, it is rare that techniquesin textile industry are applied to the manufacture of the speakervibrating diaphragm. As a result, the requirements such as thecomposition of fabric materials, the ratio of number of threads and thelike for manufacturing the speaker vibrating diaphragm are restrictedwithin the conventional process performed by traditional textilefactories. For example, when manufacturing a speaker vibratingdiaphragm, if the speaker vibrating diaphragm is manufactured by afabric composed of a plurality of materials, it is first required to mixand twist the plurality of raw materials with a specific ratio intoyarns as warps and wefts for weaving, so that a fabric with a specificmaterial ratio and yarn count can be obtained. Since this manufacturingmethod requires mixing and twisting materials into yarns, a highmanufacturing cost is required.

SUMMARY OF THE INVENTION

A primary objective of the present invention is to provide amanufacturing method of a speaker vibrating diaphragm by controlling aratio of fiber materials, so that the requirement of conventional fabricfor manufacturing a speaker vibrating diaphragm is alleviated and theprocessing expense of weaving the fabric is reduced.

In order to achieve the above objective, the present invention providesa manufacturing method of a speaker vibrating diaphragm by controlling aratio of fiber materials, the method comprising the steps of:

(A) fabric provision: providing a fabric interwoven by a plurality ofwarps and a plurality of wefts, the warps composed by sequentially andalternatively arranging a plurality of double-stranded first yarns, aplurality of single-stranded second yarns, a plurality ofdouble-stranded third yarns, a plurality of single-stranded fourth yarnsand a plurality of double-stranded fifth yarns, the wefts composed bysequentially and alternatively arranging a plurality of double-strandedfirst yarns, a plurality of single-stranded second yarns, a plurality ofdouble-stranded third yarns, a plurality of single-stranded fourth yarnsand a plurality of double-stranded fifth yarns, each of thedouble-stranded first yarns composed of 50% first fiber and 50% secondfiber, each of the single-stranded second yarns composed of 100% firstfiber, each of the double-stranded third yarns composed of 50% thirdfiber and 50% first fiber, each of the single-stranded fourth yarnscomposed of 100% second fiber, and each of the double-stranded fifthyarns composed of 50% third fiber and 50% fourth fiber;

(B) impregnation: impregnating the fabric in a resin solution;

(C) drying: drying the fabric impregnated with resin solution;

(D) formation: pressing the dried resin-impregnating fabric to form apredetermined shape; and

(E) cutting: cutting the formed speaker vibrating diaphragm from thefabric fiber.

In one embodiment, the first fiber is polyester fiber, the second fiberis rayon fiber, the third fiber is aramid fiber, and the fourth fiber iscotton fiber.

Preferably, each of the double-stranded first yarns, the double-strandedthird yarns and the double-stranded fifth yarns has a first yarn count,each of the single-stranded second yarns and the single-stranded fourthyarns has a second yarn count, and the first yarn count is less than thesecond yarn count.

Preferably, the first yarn count is 20 and the second yarn count is 40.

The present invention is thereby beneficial in alleviating therequirement of conventional fabric for manufacturing conventionalspeaker vibrating diaphragms and reducing the processing expense ofweaving fabric materials.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram illustrating the structure of aconventional speaker;

FIG. 2 is a perspective view of a damper of the speaker;

FIG. 3 is a flow diagram of the processing steps of the presentinvention;

FIG. 4 illustrates the manufacturing process of the present invention;

FIG. 5A is a partial enlarged view of Embodiment 1;

FIG. 5B is a partial enlarged view of Embodiment 2;

FIG. 5C is a partial enlarged view of Embodiment 3; and

FIG. 5D is a partial enlarged view of Embodiment 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The accompanying drawings and reference symbols are included toillustrate embodiments of the present invention so that the inventioncan be implemented by a skilled person.

Referring to FIG. 3 and FIG. 4, which show a flow diagram and amanufacturing process of the present invention respectively. The stepsare illustrated hereafter.

Fabric provision (step S1): a fabric 20 is provided. The fabric 20 isinterwoven by a plurality of warps and a plurality of wefts (not shown).Each of the plurality of warps of the fabric 20 has an individual yarncount and material composition, and each of the plurality of wefts ofthe fabric has an individual yarn count and material composition. Bycontrolling a combination of the yarn counts of the plurality of warpsand the plurality of wefts, a total number of threads and a materialcomposition ratio of the warps and wefts required for the speakervibrating diaphragm are achieved.

Impregnation (step S2): the fabric 20 is impregnated in a resin solution30. In general, resin component can be selected from one or acombination of a group consisting of phenolic resin, epoxy resin, andpolyester resin, or from other resin materials possessing with a sameproperty.

Drying (step S3): the fabric 20 impregnated with resin solution isdried. More specifically, the fabric 20 is transferred to a dryingdevice 40 for drying the resin on the fabric 20, such that the fabric 20is provided with appropriate hardness, elasticity and toughness.

Formation (step S4): after drying the fabric 20 impregnated with resinsolution, the fabric 20 is pressed to form a predetermined shape. Morespecifically, the fabric 20 is transferred to a heat pressing formationdevice 50 which includes a heating device and a formation mold(comprised of an upper mold and a lower mold). The formation mold isheated to a predetermined temperature and presses the fabric 20 from upand down, such that a predetermined shape of the speaker vibratingdiaphragm is formed after pressuring and heating the fabric 20.

The formation condition and temperature are determined based on thecomposition of the fabric and resin solution. In general, the formationtemperature of cotton fibers is 245° C.±30° C.; the formationtemperature of polyester fibers is 200° C.±30° C.; and the formationtemperature of aramid fibers is 240° C.±35° C.

Cutting (step S5): the formed speaker vibrating diaphragm is cut fromthe fabric 20 to obtain a speaker vibrating diaphragm 12. Morespecifically, the fabric 20 is transferred to a cutting device 60 to cutthe speaker vibrating diaphragm with a predetermined shape from thefabric 20 to obtain the speaker vibrating diaphragm 12. The speakervibrating diaphragm 12 formed in the figure is a damper, yet otherelements of vibrating system such as the cone paper or the connectingmember can be manufactured via the same process.

Embodiment 1

As for the conventional manufacturing method, when a speaker dampercomposed of 50% polyester fibers and 50% rayon fibers with a yarn countof 20 is to be manufactured, the conventional manufacturing method hasto mix and twist two materials of fibers with a specific ratio intoyarns first. Then, the yarns are used as warps and wefts to be woven toobtain a fabric material with a specific material ratio and yarn count.Since this manufacturing method first requires mixing and twistingpolyester fibers and rayon fibers into yarns, the process of mixing andtwisting requires high processing expense.

However, in the step of fabric provision of the manufacturing method inthe present invention, the total number of threads and the materialcomposition ratio of warps and wefts required by the speaker vibratingdiaphragm are achieved by controlling the combination of yarn counts ofthe plurality of warps and the plurality of wefts of the fabric.Referring to FIG. 5A, FIG. 5A shows a partial enlarged view ofEmbodiment 1. Taken embodiment 1 as the example, the partial enlargedview of the fabric 20 shows that the warps are composed by sequentiallyand alternatively arranging 100% polyester fibers P1, P2, P3 with yarncounts of 20 and 100% rayon fibers R1, R2, R3 with yarn counts of 20,and the wefts are composed by sequentially and alternatively arranging100% polyester fibers P4, P5, P6 with yarn counts of 20 and 100% rayonfibers R4, R5, R6 with yarn counts of 20 (as shown in Table 1).

According to the improved manufacturing method of Embodiment 1, massproduced, low cost and easily available 100% polyester fibers and 100%rayon fibers can be used directly as warps and wefts to be arrangedalternatively and woven to fabric material as the fabric formanufacturing the speaker vibrating diaphragm. As a result, theprocessing expense of mixing and twisting different raw materials with aspecific ratio into a yarn can be omitted. In the industry of speakerelement which has low gross margin and consumes a great amount ofmanpower and time, the manufacturing method is novel and it greatlyreduces processing cost and time required for production.

TABLE 1 Fiber composition and yarn counts of the warps and wefts inEmbodiment 1 Fiber Polyester Rayon Polyester Rayon Polyester Rayonmaterial/Number Fiber P1 Fiber R1 Fiber P2 Fiber R2 Fiber P3 Fiber R3warps Yarn count (S) 20 20 20 20 20 20 Fiber Polyester Rayon PolyesterRayon Polyester Rayon material/Number Fiber P4 Fiber R4 Fiber P5 FiberR5 Fiber P6 Fiber R6 wefts Yarn count (S) 20 20 20 20 20 20

Embodiment 2

If a speaker damper composed of ⅔ polyester fibers and ⅓ rayon fiberswith a yarn count of 20 is to be manufactured, the conventionalmanufacturing method first requires preparing two materials of fibers,mixing and twisting the fibers with a specific ratio of 2:1 into yarns,and using the yarns as warps and wefts to be woven to obtain a fabricmaterial with a specific material ratio and yarn count. Thisconventional manufacturing method also requires the process of mixingand twisting with a high manufacturing cost.

Referring to FIG. 5B, FIG. 5B shows a partial enlarged view ofEmbodiment 2. In Embodiment 2, the threads ratio and the arrangementorder of the warps and wefts can be altered to obtain the required totalnumber of threads and material composition ratio of the warps and wefts.Taking Embodiment 2 as the example, the warps are composed bysequentially and alternatively arranging 100% polyester fibers P1, P2,P3, P4 with yarn counts of 20 and 100% rayon fibers R1, R2 with yarncounts of 20, and the wefts are composed by sequentially andalternatively arranging 100% polyester fibers P5, P6, P7, P8 with yarncounts of 20 and 100% rayon fibers R3, R4 with yarn counts of 20 (asshown in Table 2).

TABLE 2 Fiber composition and yarn counts of the warps and wefts inEmbodiment 2 Fiber Polyester Polyester Rayon Polyester Polyester Rayonmaterial/Number Fiber P1 Fiber P2 Fiber R1 Fiber P3 Fiber P4 Fiber R2warps Yarn count (S) 20 20 20 20 20 20 Fiber Polyester Polyester RayonPolyester Polyester Rayon material/Number Fiber P5 Fiber P6 Fiber R3Fiber P7 Fiber P8 Fiber R4 wefts Yarn count (S) 20 20 20 20 20 20

Embodiment 3

Furthermore, a speaker damper composed of ⅔ polyester fibers and ⅓ rayonfibers with a yarn count of 20 can be achieved by adjusting fibers withdifferent yarn counts.

Referring to FIG. 5C, FIG. 5C shows a partial enlarged view ofEmbodiment 3. In Embodiment 3, a speaker damper with required materialcomposition ratio is obtained by alternating yarn counts of part of thewarps and wefts. For example, if a speaker vibrating diaphragm composedof ⅔ polyester fibers and ⅓ rayon fibers with a yarn count of 20 is tobe manufactured, the warps can be composed by sequentially andalternatively arranging 100% polyester fibers P1, P2, P3 with yarncounts of 20 and 100% rayon fibers R1, R2, R3 with yarn counts of 40,and the wefts can be composed by sequentially and alternativelyarranging 100% polyester fibers P4, P5, P6 with yarn counts of 20 and100% rayon fibers R4, R5, R6 with yarn counts of 40 (as shown in Table3).

By this way of arranging the warps and wefts with different yarn countsand material compositions, the required specific material compositionratio can be achieved. In Embodiment 3, fibers composed of 100% of asingle material are used with combinations of different yarn counts andmaterial combinations to achieve the same object. As a result, theprocess of mixing and twisting threads can be omitted and high expensesthereof can be reduced.

TABLE 3 Fiber composition and yarn counts of the warps and wefts inEmbodiment 3 Fiber Polyester Rayon Polyester Rayon Polyester Rayonmaterial/Number Fiber P1 Fiber R1 Fiber P2 Fiber R2 Fiber P3 Fiber R3warps Yarn count (S) 20 40 20 40 20 40 Fiber Polyester Rayon PolyesterRayon Polyester Rayon material/Number Fiber P4 Fiber R4 Fiber P5 FiberR5 Fiber P6 Fiber R6 wefts Yarn count (S) 20 40 20 40 20 40

Embodiment 4

If a speaker damper composed of various material of fibers, such aspolyester fibers, rayon fibers, aramid fibers, cotton fibers, inspecific ratio is to be composed, the conventional manufacturing methodrequires first preparing the various materials of fibers, mixing andtwisting the fibers with a specific ratio into yarns, and using theyarns as warps and wefts to be woven to obtain a fabric material with aspecific material ratio and yarn count. This process of mixing andtwisting various materials has a higher processing expense than theprocess of mixing and twisting only two materials. In addition, thistype of speaker damper with special material ratio specified by aspeaker damper factory must be customized. As a result, themanufacturing cost of the speaker damper is higher.

Referring to FIG. 5D, FIG. 5D shows a partial enlarged view ofEmbodiment 4. In Embodiment 4, the total number of threads and thematerial composition ratios of the warps and wefts required can beachieved by collocating material fibers with different compositions andusing specified number of threads ratio and arrangement order.

The warps are composed by sequentially and alternatively arranging aplurality of double-stranded first yarns PR, a plurality ofsingle-stranded second yarns P, a plurality of double-stranded thirdyarns AR, a plurality of single-stranded fourth yarns R, and a pluralityof double-stranded fifth yarns AC. Each of the double-stranded firstyarns PR is composed of 50% first fiber and 50% second fiber, each ofthe single-stranded second yarns is composed of 100% first fiber, eachof the double-stranded third yarns AR is composed of 50% third fiber and50% first fiber, each of the single-stranded fourth yarns R is composedof 100% second fiber, and each of the double-stranded fifth yarns AC iscomposed of 50% third fiber and 50% fourth fiber (as shown in Table 4).

The wefts are composed by sequentially and alternatively arranging aplurality of double-stranded first yarns PR, a plurality ofsingle-stranded second yarns P, a plurality of double-stranded thirdyarns AR, a plurality of single-stranded fourth yarns R, and a pluralityof double-stranded fifth yarns AC. Each of the double-stranded firstyarns PR is composed of 50% first fiber and 50% second fiber, each ofthe single-stranded second yarns is composed of 100% first fiber, eachof the double-stranded third yarns AR is composed of 50% third fiber and50% first fiber, each of the single-stranded fourth yarns R is composedof 100% second fiber, and each of the double-stranded fifth yarns AC iscomposed of 50% third fiber and 50% fourth fiber (as shown in Table 4).

The first fiber is polyester, the second fiber is rayon fiber, the thirdfiber is aramid fiber, and the fourth fiber is cotton fiber.

Each of the double-stranded first yarns PR, the double-stranded thirdyarns AR and the double-stranded fifth yarns AC has a first yarn count.Each of the single-stranded second yarns P and the single-strandedfourth yarns R has a second yarn count. The first yarn count is lessthan the second yarn count. Preferably, the first yarn count is 20 andthe second yarn count is 40. In other words, each of the double-strandedfirst yarns PR has a yarn count of 20, each of the single-strandedsecond yarns P has a yarn count of 40, each of the double-stranded thirdyarns AR has a yarn count of 20, each of the single-stranded fourthyarns R has a yarn count of 40, and each of the double-stranded fifthyarns AC has a yarn count of 20 (as shown in Table 4).

Embodiment 4 shows a further applicable example, in which variousmaterials including polyester fibers, rayon fibers, aramid fibers andcotton fibers etc. that can be applied as the speaker damper are takento be used as 100% single yarns, or composite yarns (double-stranded,triple-stranded, quadruple-stranded, etc.) mixed and twisted by at leasttwo materials with specific ratios, and arranged with different yarncounts. In addition to the possible combinations thereof, the sequentialorder in warps and wefts are sorted to mix and weave a fabric meetingspecific requirements as a fabric for manufacturing a speaker vibratingdiaphragm. Although Embodiment 4 similarly uses double-stranded fibers,composite yarns (double-stranded, triple-stranded, quadruple-strandedfibers, etc.) that are non-customized and have a common material mixingratio can be used so that the manufacturing cost is still lower thanconventional customized yarns by mixing and twisting materials.

TABLE 4 Fiber composition and yarn counts of the warps and wefts inEmbodiment 4 First Yarn Third Yarn Fifth Yarn (First Fiber: (ThirdFiber: (Third Fiber: Polyester Fiber + Second Yarn Aramid Fiber + FourthYarn Aramid Fiber + Fiber Second Fiber: (First Fiber: First Fiber:(Second Fiber: Fourth Fiber: material/Number Rayon Fiber) PR PolyesterFiber) P Polyester Fiber) AR Rayon Fiber) R Cotton Fiber) AC Warps YarnCount (S) 20 40 20 40 20 First Yarn Third Yarn Fifth Yarn (First Fiber:(Third Fiber: (Third Fiber: Polyester Fiber + Second Yarn Aramid Fiber +Fourth Yarn Aramid Fiber + Fiber Second Fiber: (First Fiber: FirstFiber: (Second Fiber: Fourth Fiber: material/Number Rayon Fiber) PRPolyester Fiber) P Polyester Fiber) AR Rayon Fiber) R Cotton Fiber) ACWefts Yarn Count (S) 20 40 20 40 20

The above description is only for illustrating the preferred embodimentsof the present invention, but not for restricting the present inventionin any forms. It is apparent to those skilled in the art that a varietyof modifications and changes may be made without departing from thescope of the present invention which is intended to be defined by theappended claims.

What is claimed is:
 1. A manufacturing method of a speaker vibratingdiaphragm by controlling a ratio of fiber materials, the methodcomprising the steps of: (A) fabric provision: providing a fabricinterwoven by a plurality of warps and a plurality of wefts, the warpscomposed by sequentially and alternatively arranging a plurality ofdouble-stranded first yarns, a plurality of single-stranded secondyarns, a plurality of double-stranded third yarns, a plurality ofsingle-stranded fourth yarns and a plurality of double-stranded fifthyarns, the wefts composed by sequentially and alternatively arranging aplurality of double-stranded first yarns, a plurality of single-strandedsecond yarns, a plurality of double-stranded third yarns, a plurality ofsingle-stranded fourth yarns and a plurality of double-stranded fifthyarns, each of the double-stranded first yarns composed of 50% firstfiber and 50% second fiber, each of the single-stranded second yarnscomposed of 100% first fiber, each of the double-stranded third yarnscomposed of 50% third fiber and 50% first fiber, each of thesingle-stranded fourth yarns composed of 100% second fiber, and each ofthe double-stranded fifth yarns composed of 50% third fiber and 50%fourth fiber; (B) impregnation: impregnating the fabric in a resinsolution; (C) drying: drying the fabric impregnated with resin solution;(D) formation: pressing the dried resin-impregnating fabric to form apredetermined shape; and (E) cutting: cutting the formed speakervibrating diaphragm from the fabric fiber.
 2. The manufacturing methodaccording to claim 1, wherein the first fiber is polyester fiber, thesecond fiber is rayon fiber, the third fiber is aramid fiber, and thefourth fiber is cotton fiber.
 3. The manufacturing method according toclaim 2, wherein each of the double-stranded first yarns, thedouble-stranded third yarns and the double-stranded fifth yarns has afirst yarn count, each of the single-stranded second yarns and thesingle-stranded fourth yarns has a second yarn count, and the first yarncount is less than the second yarn count.
 4. The manufacturing methodaccording to claim 3, wherein the first yarn count is 20 and the secondyarn count is
 40. 5. The manufacturing method according to claim 1,wherein each of the double-stranded first yarns, the double-strandedthird yarns and the double-stranded fifth yarns has a first yarn count,each of the single-stranded second yarns and the single-stranded fourthyarns has a second yarn count, and the first yarn count is less than thesecond yarn count.
 6. The manufacturing method according to claim 5,wherein the first yarn count is 20 and the second yarn count is 40.